A Grab Bag Full of FAQs

 

We’re reaching into the seize bag to reply your high questions on industrial air compressor upkeep and system design.

Don’t see your query answered right here? Contact us with some other points which are in your thoughts. One in every of our compressed air system consultants shall be completely satisfied to assist!

1. How do I eliminate used air compressor oil?

Air compressor oil is poisonous to people and animals and may trigger issues within the setting if it isn’t disposed of correctly. The Environmental Safety Company (EPA) regulates disposal of used oil from air compressors and different industrial gear. Each the oil and oil filters have to be disposed of correctly to keep up compliance and keep away from pricey fines.

  • Used air compressor oil (together with petroleum-based and artificial oils) may be recycled or refined right into a decrease grade of oil or gasoline. Search for a registered used oil assortment heart in your space. Be sure used oil is tightly sealed in spill-proof containers. Many service stations and auto elements shops are additionally registered oil assortment facilities; in the event you solely accumulate a small quantity of oil for recycling, you might be able to accomplice with one in every of these native companies. Bigger retailers ought to look to their state hazardous waste program for oil recycling directions.
  • Oil filters must be punctured and hot-drained or crushed previous to disposal. Alternatively, you might be able to flip in your used oil filters on the identical facility that collects your used oil.
  • Oil collected by your oil/water separator should even be disposed of correctly. Add this oil to the oil you accumulate throughout oil modifications for recycling.

2. How typically ought to I take an oil pattern for my air compressor?

Oil sampling is performed to watch the situation of your oil and preserve your air compressor in peak working situation. It’s a comparatively cheap preventive upkeep device. Oil sampling is often performed each 2,000 hours. With new gear, you might need to pattern extra often—as typically as each 500-1,000 hours—to find out the perfect oil change intervals in your working patterns. Your guarantee might specify oil sampling intervals, so test your consumer’s guide and guarantee paperwork.

The oil pattern is distributed to a lab for evaluation. An oil evaluation offers information on oil viscosity, particulate concentrations and composition, pH ranges and the presence of damage metals. This info is used to optimize oil change intervals in your utilization patterns and setting—for instance, in case you are working in a really soiled setting, the oil pattern might present that try to be altering oil extra often than the usual PM intervals in your consumer’s guide. Sampling can even assist to diagnose rising issues with the compressor, similar to varnish buildup or extra put on of metallic elements. Common oil sampling will reduce surprising downtime and preserve your air compressor working at peak efficiency.

3. How can I make my air compressor quieter?

Air compressors may be fairly loud. A reciprocating air compressor sometimes operates at noise ranges of as much as 85 decibels (dB), whereas rotary screw air compressors vary from 70-75 dB. There are a selection of steps you possibly can take to show down the amount.

  • Select a quieter compressor. If the compressor shall be operated close to areas the place persons are working, it could be price contemplating decibel ranges in your shopping for choice. As famous above, rotary screw air compressors are usually quieter than reciprocating compressors, however even throughout the identical kind there are variations in dB ranges. When evaluating items, do not forget that the decibel scale is logarithmic. A 3-dB enhance means about double the noise, and a 10-dB distinction will increase perceived noise ranges by an element of 10. At 85 dB, you need to increase your voice to be heard.
  • Place the compressor in a sound-proof enclosure or a separate space with sound dampening supplies similar to foam board or acoustic panels. It’s also possible to hold sound blankets within the compressor room or drape them over the compressor enclosure to dampen noise.
  • Wrap the compressor. Sound blankets may be wrapped straight across the compressor itself to soak up noise from the pistons or rotors. Make it possible for the fabric doesn’t block the inlet, exhaust, cords or hoses.
  •  Set up an consumption silencer. Plenty of the noise from an air compressor resonates from the air consumption, which might create high-frequency pulsating noises. These muffling gadgets use tubes or sound-deadening supplies to dampen the sound of inrushing air. They could additionally act as consumption filters.
  • Put a rubber mat underneath the compressor. This can dampen vibrations between the compressor and the ground. It’s also possible to use rubber grommets on the air compressor mount.
  • Be sure your unit is in good working situation. Examine your unit usually and carry out all beneficial PM. Tighten up any unfastened bolts or screws that trigger the unit to rattle, monitor lubrication ranges, test your bearings and belts, and alter air filters usually. A well-maintained air compressor will run quieter (and last more).

4. Does my backup air compressor should be the identical measurement as my fundamental air compressor?

Not essentially. It is dependent upon what you want your backup air compressor to do and the way reliant your operations are on steady compressed air. There are a number of methods to consider sizing your fundamental and backup air compressors.

  • Emergency backup: On this state of affairs, the secondary compressor is just used if the first compressor fails. It could be a smaller measurement than your fundamental compressor. This works effectively in the event you can simply scale manufacturing or have a small variety of “important” air-using processes and different much less important purposes. For instance, you might have a 50HP fundamental air compressor that may deal with all of your air wants at most manufacturing capability. Your backup could also be a 25HP compressor—not sufficient to ramp everybody as much as full pace, however sufficient to keep away from shutting down your complete operation whereas the primary compressor is being repaired.
  • Auxiliary energy: On this state of affairs, the secondary compressor is used each as an emergency backup and as an auxiliary compressor for durations of excessive demand. This lets you have a smaller fundamental compressor. The backup would be the identical measurement and even smaller. The 2 compressors work in parallel when demand is at a peak. This works effectively for outlets with extremely variable demand patterns.
  • Full redundancy: In some circumstances, having a steady air provide is completely important. When demand is steady and constant, it could be price investing in a completely redundant compressed air system. Each compressors on this state of affairs are sized to deal with the utmost compressed air demand for the ability. When the first unit is offline for upkeep or restore, the secondary unit takes over. It’s also possible to periodically swap between the machines to even out put on and tear.

5. Why does my compressor shut down at excessive temperatures?

Industrial air compressors embody a temperature sensor and swap that may flip the compressor motor off if it begins to overheat. This is essential to stop pricey injury to your compressor. When ambient temperatures are excessive, the motor is extra susceptible to overheating, and also you usually tend to see your motor shut down unexpectedly.

You may scale back unplanned shutdowns as a result of air compressor overheating by preserving the compressor cooler and making certain that there’s ample air flow across the compressor. In case your compressor is situated outdoors, shading the world may also help. If the air compressor is inside, be sure that the compressor room has ample air flow.

Overheating can be brought on by different points, similar to plugged oil filters, loaded air filters, low oil ranges or the improper kind of lubricant. Typically, a defective temperature swap can even trigger extreme shutdowns. In case your air compressor is shutting down often and you’ve got already addressed air flow, cooling, filters and lubrication, contact a professional restore technician to repair the issue.

6. Why do the fuses for my air compressor preserve blowing?

In case your air compressor retains tripping its circuit breaker, it is a clear indication that one thing is improper, both with the wiring or with the compressor itself. First, just remember to are utilizing {an electrical} supply with the precise voltage in your air compressor. A big air compressor must be plugged straight into an outlet with the suitable voltage for the machine, utilizing a heavy-duty energy twine with the suitable score. Examine your consumer’s guide for particulars.

If the wiring and electrical system take a look at, blown fuses might point out an issue with the compressor that’s inflicting it to overheat or draw an excessive amount of energy. Widespread culprits embody:

  • Soiled air filter
  • Defective motor (e.g., sparking or arcing contained in the motor)
  • Defective circuit breaker
  • Clogged pistons or points with bearings or rotors
  • Overuse/extreme responsibility cycles
  • Caught centrifugal swap
  • Shorted strain swap
  • Failure of unloading valve

For those who’re undecided what’s inflicting your air compressor to blow fuses, it is best to have it checked by a professional service technician as quickly as doable.

7. Is it regular to have some residual oil in my compressed air tank?

It’s not unusual for an oil-lubricated air compressor to go hint a

quantities of oil. This is named “oil carryover.” Small quantities of oil might seem in your air receiver tank or be current within the compressed air provide. You may scale back oil carryover with an inline filter. A coalescing filter will take away each oil mists and dry particulate from compressed air.

Nonetheless, in the event you discover oil pooling within the air tank or in or across the outdoors of your compressor, it is a downside. Oil pooled across the compressor signifies a leak someplace in your compressor. Oil pooled within the tank might imply that the air/oil separator has failed. These are pressing issues that have to be addressed earlier than persevering with to function the machine.

8. How do I drain water from my compressed air tank?

Draining the condensate that builds up inside your compressed air system is essential. Moisture buildup contained in the tank, pipes or compressor will trigger corrosion over time. Within the air tank, condensation will pool on the backside of the tank, the place it may be drained utilizing a drain valve. For guide drain valves, merely open the valve and permit water to empty out right into a container or ground drain till it stops working, often only some seconds. This must be carried out no less than as soon as per day and will should be carried out a number of occasions per day.

You may scale back upkeep with an automatic drain valve.

  • Electrical drain valves open on a timer to empty water. They are often set to open for just a few seconds at a time on a daily schedule, similar to as soon as a minute or as soon as an hour.
  • A zero-loss drain valve makes use of a float mechanism to set off the valve opening. This reduces air loss as a result of the drain valve is just open when wanted.

Drain valves may additionally be discovered on compressors, air dryers, inline filters and at low factors within the compressed air piping. They need to be used wherever moisture might accumulate within the compressed air system.

 

That’s all that’s on this seize bag! You probably have further questions, submit them by means of our contact type or name us to speak to an professional. 





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